Full text of "Yamaha Virago XV535 Owners Manual"

YAMAHA 



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OWNER'S MANUAL 


LIT-1 1626-1 3-1 6 


Virago 

XV535M 
XV535MC 





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Dear New Yamaha ATV Owner: 

CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased a quality 
Yamaha product that, with proper use and care, will provide hours of riding pleasure. BEFORE YOU 
OPERATE YOUR NEW ATV, Yamaha recommends these important points: 

e READ YOUR OWNER'S MANUAL 



> 



• A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR I 
GREATER _ 

• A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER ^ 
THAN 90CC LL 

• TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA - ASK YOUR DEALER FOR UJ 
DETAILS OR CALL 1-800-887-2887 f£ 

If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha 
dealership and were not informed of the age recommendation for your ATV by the dealership, please 
fill out the information below and mail this card to Yamaha today. ^i 

Name: ATV Model: Purchase Date: 



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MO. OAY 

Address: Primary I.D (Engine Number): 



Dealer Name & Address: 



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Telephone: 
( ) 



BUSINESS REPLY MAIL 



FIRST CLASS 



PERMIT NO. 4 



CYPRESS, CA 



POSTAGE WILL BE PAID BY ADDRESSEE 

YAMAHA MOTOR CORPORATION U.S.A. 

P.O. BOX 6555 

CYPRESS, CALIFORNIA 90630-9989 



NO POSTAGE 

NECESSARY 

IF MAILED 

IN THE 

UNITED STATES 



ATTN: SALES ADMINISTRATION 



II.ImII.„,II„„II,II,„I.ImI.I„I„I,I,I„I„.II 



INTRODUCTION 



Congratulations on your purchase of the Yamaha XV535/XV535C. This model is the 
result of Yamaha's vast experience in the production of fine sporting, touring, and pac- 
esetting racing machines. It represents the high degree of craftsmanship and reliability 
that have made Yamaha a leader in these fields. 

This manual will give you an understanding of the operation, inspection, and basic 
maintenance of this motorcycle. If you have any questions about the operation or main- 
tenance of your motorcycle, please consult a Yamaha dealer. 

The design and manufacture of this Yamaha motorcycle fully comply with the emis- 
sions standards for clean air applicable at the date of manufacture. Yamaha has met 
these standards without reducing the motorcycle's performance or economy of opera- 
tion. To maintain these high standards, it is important that you and your dealer pay 
close attention to the recommended maintenance schedules and operating instructions 
contained within this manual. 



IMPORTANT MANUAL INFORMATION 



Particularly important information is distinguished in this manual by the following notations: 



A 



The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY 
IS INVOLVED! 



A WARNING 



Failure to follow WARNING instructions could result in severe injury or death to 
the motorcycle operator, a bystander or a person inspecting or repairing the 
motorcycle. 



CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to 

the motorcycle. 



NOTE: 



A NOTE provides key information to make procedures easier or clearer. 



NOTE: 

• This manual should be considered a permanent part of this motorcycle and should remain with it 
even if the motorcycle is subsequently sold. 

• Yamaha continually seeks advancements in product design and quality. Therefore, while this 
manual contains the most current product information available at the time of printing, there may 
be minor discrepancies between your motorcycle and this manual. If there is any question con- 
cerning this manual, please consult your Yamaha dealer. 



IMPORTANT MANUAL INFORMATION 



A WARNING 



PLEASE READ THIS MANUAL AND THE "YOU AND YOUR MOTORCYCLE: RIDING TIPS" 
BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO 
NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED A SATISFAC- 
TORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE 
BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND 
CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU 
SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. 



AFFIX DEALER 
LABEL HERE 



XV535M/XV535MC 

OWNER'S MANUAL 

3 1999 by Yamaha Motor Corporation, U.S.A. 

1st Edition, May 1999 

All rights reserved. Any reprinting or 

unauthorized use without the written 

permission of Yamaha Motor Corporation, 

U.S.A. is expressly prohibited. 



P/NLIT-1 1626-1 3-1 6 



TABLE OF CONTENTS 



1 SAFETY INFORMATION 

2 DESCRIPTION 

3 INSTRUMENT AND CONTROL FUNCTIONS 

4 PRE-OPERATION CHECKS 

5 OPERATION AND IMPORTANT RIDING POINTS 

6 PERIODIC MAINTENANCE AND MINOR REPAIR 

7 CLEANING AND STORAGE 

8 SPECIFICATIONS 

9 CONSUMER INFORMATION 
INDEX 



dS SAFETY INFORMATION 



Safety information 1-1 

Safe riding 1-1 

Protective apparel 1-2 

Modification 1-3 

Loading and accessories 1-3 

Gasoline and exhaust gas 1-5 

Location of the important labels 1-7 



A SAFETY INFORMATION 



TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERA- 
TION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EX- 
PERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING 
REQUIREMENTS BEFORE RIDING. 
HE OR SHE SHOULD: 

1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF 
MOTORCYCLE OPERATION. 

2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER'S MANUAL. 

3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. 

4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER'S MANUAL 
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS. 

Safe riding 

1 . Always make pre-operation checks. Careful checks may help prevent an accident. 

2. This motorcycle is designed to carry the operator and a passenger. 

3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of au- 
tomobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not 
see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance 
of this type of accident. 

Therefore: 

a. Wear a brightly colored jacket. 

b. Use extra caution when you approach and pass through intersections, since intersections are the 
most likely places for motorcycle accidents. 

c. Ride where other motorists can see you. Avoid riding in another motorist's "blind spot". 

1-1 



£S SAFETY INFORMATION 



4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in 
accidents do not even have a current motorcycle license. 

a. Make sure you are qualified. Also, only lend your motorcycle to experienced operators. 

b. Know your skills and limits. Staying within your limits may help you to avoid an accident. 

c. We recommend that you practice riding your motorcycle where there is no traffic until you have be- 
come thoroughly familiar with your motorcycle and all of its controls. 

5. Many motorcycle accidents have been caused by motorcycle operator errors. A typical error made by 
the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean 
angle for the speed). 

a. Always obey the speed limits and never travel faster than warranted by road and traffic conditions. 

b. Always signal before turning or changing lanes. Make sure other motorists see you. 

6. The operator's and passenger's posture are important for proper control. 

a. The operator should keep both hands on the handlebars and both feet on the operator footrests 
during operation to maintain control of the motorcycle. 

b. The passenger should always hold on to the operator, or the seat strap or grab bar if the motorcycle 
is so equipped, with both hands and keep both feet on the passenger footrests. 

c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests. 

7. Never ride under the influence of alcohol or drugs. 

8. This motorcycle is designed for on-road use only. It is not suitable for off-road use. 

Protective apparel 

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety hel- 
met is the single most critical factor in the prevention or reduction of head injuries. 

1 . Always wear an approved helmet. 



1-2 



A SAFETY INFORMATION 



2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vi- 
sion which could delay seeing a hazard. 

3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing abrasions or 
lacerations. 

4. Never wear loose fitting clothing. It could catch on the control levers, footrests, or wheels and cause in- 
jury or accident. 

5. Never touch the engine or exhaust system during or after operation. They become very hot and can 
cause burns. Always wear protective clothing that covers your legs, ankles, and feet. 

6. A passenger should also observe the above precautions. 

Modification 

Modifications made to the motorcycle not approved by Yamaha, or the removal of original equipment, may 
render your motorcycle unsafe for use and may cause severe personal injury. Modifications may also 
make your motorcycle illegal to use. 

Loading and accessories 

Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight 
distribution of the machine is changed. To avoid the possibility of an accident, extreme caution should be 
used if adding cargo or accessories to your motorcycle. Use extra care if riding a motorcycle which has 
added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding acces- 
sories to your motorcycle: 

Loading 

The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load 
limit of XV535 : 485 lb (220 kg) / XV535C : 483 lb (219 kg). 

1-3 



A SAFETY INFORMATION 



When loading within these weight limits, keep the following in mind: 

1 . Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Be sure to 
distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or in- 
stability. 

2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely 
attached to the motorcycle before riding. Recheck accessory mounts and cargo restraints frequently. 

3. Never attach any large or heavy items to the handlebars, front forks, or front fender. These items, in- 
cluding such cargo as sleeping bags, duffle bags, or tents, can create unstable handling or slow steer- 
ing response. 

Accessories 

Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha 
cannot test all other accessories which may be available, you must personally be responsible for the prop- 
er selection, installation and use of non-Yamaha accessories. You should use extreme caution when se- 
lecting and installing any accessories. 

Keep in mind these guidelines for mounting accessories in addition to those provided under "LOADING". 

1 . Never install accessories or carry cargo that would impair the performance of your motorcycle. Care- 
fully inspect the accessory before using it to make sure it does not in any way reduce ground clearance 
or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or 
reflectors. 

a. Accessories fitted to the handlebar or the front fork area can create instability due to improper 
weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork 
area, they must be as lightweight as possible and should be kept to a minimum. 



1-4 



/h SAFETY INFORMATION 



b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic 
effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross 
winds. These accessories may also cause instability when being passed by or passing large vehi- 
cles. 

c. Certain accessories can displace the operator from his or her normal riding position. This improper 
position limits the freedom of movement of the operator and may limit control ability. Therefore 
such accessories are not recommended. 

2. Caution must be used if adding electrical accessories. If these accessories exceed the capacity of the 
motorcycle's electrical system, an electric failure could result, which could cause a dangerous loss of 
lights or engine power. 

Gasoline and exhaust gas 

1. GASOLINE IS HIGHLY FLAMMABLE: 

a. Always turn off the engine when refueling. 

b. Take care not to spill any gasoline on the engine or exhaust system when refueling. 

c. Never refuel while smoking or in the vicinity of an open flame. 

2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poi- 
sonous and may cause loss of consciousness and death within a short time. Always operate your 
motorcycle in an area that has adequate ventilation. 

3. Always turn off the engine before leaving the motorcycle unattended and remove the ignition key. 
When parking the motorcycle, note the following: 

a. The engine and exhaust system may be hot. Park the motorcycle in a place where pedestrians or 
children are not likely to touch these hot areas. 

b. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over. 

c. Do not park the motorcycle near a flammable source, e.g. a kerosene heater, or near an open 
flame. The motorcycle could catch fire. 

1-5 



A SAFETY INFORMATION 



4. When transporting the motorcycle in another vehicle, be sure it is kept upright and that the fuel cock is 
turned to "ON" or "RES" (for vacuum type) / "OFF" (for manual type). If it should lean over, gasoline 
may leak out of the carburetor or fuel tank. 

5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get in your eyes, 
see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash it off with 
soap and water and change your clothes. 



1-6 



A SAFETY INFORMATION 



Location of the important labels 

Please read the following labels carefully before operating this motorcycle. 




1-7 



A SAFETY INFORMATION 



AWARNING 



• BEFORE YOU OPERATE THIS VEHICLE, READ 
THE OWNER'S MANUAL AND ALL LABELS. 

• ALWAYS WEAR AN APPROVED MOTORCYCLE 
HELMET, eye protection, and protective clothing. 



3MX-2118K-A0 



3 California only 





EMISSION HOSE ROUTING 


CARB. 

•S- FROM 

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TO ATMOSPHERE 





4YN-21 686-00 J 



CAUTION 



Read owner's manual before servicing battery. 

Electrolyte will damage metal parts or paint. 
If electrolyte spills, wash area with fresh 
water immediately. 

Be sure to connect breather hose after 
installing battery. 



3JL-28177-A0 



TIRE INFORMATION 



Cold tire normal pressure should be set as 
follows. 

• Up to 90 kg (198 lbs) load 

FRONT : 200kPa, {2.00kgf/cm 2 }, 29psi 
REAR : 225kPa, {2.25kgf/cm 2 >, 33psi 

• 90 kg (198 lbs) ~ maximum load 

FRONT : 200kPa, {2.00kgf/cm 2 }, 29psi 
REAR : 250kPa, {2.50kgf/cm 2 >, 36psi 



1-8 



DESCRIPTION 



Left view 2-1 

Right view 2-2 

Controls/Instruments 2-3 



DESCRIPTION 



Left view 



4 5 




1 . Headlight 

2. Air filter 

3. Rider seat 

4. Tool kit 

5. Passenger seat 



(page 6-29) 
(page 6-12) 
(page 3-8) 
(page 6-1) 
(page 3-7) 



6. Rear shock absorber spring 

preload adjusting ring (page 3-9) 

7. Main switch (page 3-1) 

8. Starter (choke) "|\|" (page 3-6) 

9. Shift pedal (page 3-4) 



2-1 



Right view 



DESCRIPTION 




10. Rear turn signal light 

1 1 . Sub fuel tank 

12. Fuel tank 



(page 6-30) 
(page 3-5) 



1 3. Front turn signal / position light (page 6-30) 

14. Rear brake pedal (page 3-4) 

15. Battery (page 6-26) 



2-2 



DESCRIPTION 



Controls/Instruments 




1 . Clutch lever 


(page 3-3) 


2. Speedometer 


(page 3-2) 


3. Front brake lever 


(page 3-4) 


4. Throttle grip 


(page 6-14) 


5. Right handlebar switches 


(page 3-3) 


6. Left handlebar switches 


(page 3-2) 



INSTRUMENT AND CONTROL FUNCTIONS 



Main switch 3-1 

Indicator lights 3-1 

Speedometer 3-2 

Handlebar switches 3-2 

Clutch lever 3-3 

Shift pedal 3-4 

Front brake lever 3-4 

Rear brake pedal 3-4 

Fuel tank cap 3-5 

Fuel 3-5 

Starter (choke) "|\|" 3-6 

Steering lock 3-7 

Seats 3-7 

Helmet holder 3-8 

Rear shock absorber adjustment 3-9 

Sidestand 3-9 

Sidestand/clutch switch operation check 3-10 



INSTRUMENT AND CONTROL FUNCTIONS 




Main switch 

The main switch controls the ignition 
and lighting systems. Its operation is 
described below. 

EAU00032 

ON 

All electrical circuits are switched on, 
and the headlight, meter light, taillight, 
and front position lights come on. The 
engine can be started. The key cannot 
be removed in this position. 

EAU00038 

OFF 

All electrical circuits are switched off. 
The key can be removed in this posi- 
tion. 



1. Push 

2. Release 

3. Turn 

EAU00052 

P (Parking) 

The taillight and front position light 
come on but all other circuits are off. 
With the key at "OFF", push it into the 
main switch and release it. Then turn it 
counterclockwise to "P", and remove it. 
To cancel the parking, turn the key 
clockwise. 



1 . High beam indicator light "HIGH BEAM" 

2. Neutral indicator light "NEUTRAL" 

3. Turn indicator light "TURN" 

EAU00056 

Indicator lights 

EAU00064 

High beam indicator light "HIGH 
BEAM" 

This indicator comes on when the 
headlight high beam is used. 

EAU00062 

Neutral indicator light "NEUTRAL" 

This indicator comes on when the 
transmission is in neutral. 

EAU00059 

Turn indicator light "TURN" 

This indicator flashes when the turn 
switch is moved to the left or right. 



3-1 



INSTRUMENT AND CONTROL FUNCTIONS 




1 . Reset knob 

2. Odometer 

3. Trip odometer 

EAU00095 

Speedometer 

The speedometer shows riding speed. 
This speedometer is equipped with an 
odometer and trip odometer. The trip 
odometer can be reset to "0" with the 
reset knob. Use the trip odometer to 
estimate how far you can ride on a tank 
of fuel. This information will enable you 
to plan fuel stops in the future. 



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1 . Dimmer switch "LIGHTS" 

2. Turn signal switch 'TURN" 

3. Horn switch "HORN" 

Handlebar switches 



Dimmer switch "LIGHTS" 

Turn the switch to "HI" for the high 
beam and to "LO" for the low beam. 



Turn signal switch "TURN" 

This model is equipped with self-can- 
celing turn signals. To signal a right- 
hand turn, push the switch to the right. 
To signal a left-hand turn, push the 
switch to the left. Once the switch is re- 
leased, it will return to the center posi- 
tion and self-cancel after the 
motorcycle has traveled both about 
150 m (490 ft) and for approximately 
15 seconds. The self-canceling mech- 
anism only operates when the motor- 
cycle is moving. Therefore the signal 
will not self-cancel while you are 
stopped at an intersection. The signal 
may also be canceled manually by 
pushing the switch in after it has re- 
turned to the center position. 

EAU00130 

Horn switch "HORN" 

Press the switch to sound the horn. 



3-2 



INSTRUMENT AND CONTROL FUNCTIONS 




1. Engine stop switch "ENGINE STOP" 

2. Fuel reserve switch "FUEL" 

3. Start switch "START" 

EAU00137 

Engine stop switch "ENGINE STOP" 

The engine stop switch is a safety de- 
vice for use in an emergency such as 
when the motorcycle overturns or if 
trouble occurs in the throttle system. 
Turn the switch to "RUN" to start the 
engine. In case of emergency, turn the 
switch to "OFF" to stop the engine. 



Fuel reserve switch "FUEL" 

This switch should usually be kept 
"ON" while riding. If you run out of fuel 
while riding, move the switch to "RES" 
and refuel at the first opportunity. Then 
move the switch to "ON". 

NOTE: 

When the switch is turned to reserve 
"RES", about 2.5 L (0.5 Imp gal, 0.7 US 
gal) remain in the fuel tank. 



Start switch "START" 

The starter motor cranks the engine 
when pushing the start switch. 



CAUTION: 



See starting instructions prior to 
starting the engine. 




1 . Clutch lever 

EAU0015a 

Clutch lever 

The clutch lever is located on the left 
handlebar, and the ignition circuit cut- 
off system is incorporated in the clutch 
lever holder. Pull the clutch lever to the 
handlebar to disengage the clutch, and 
release the lever to engage the clutch. 
The lever should be pulled rapidly and 
released slowly for smooth clutch oper- 
ation. (Refer to the engine starting pro- 
cedures for a description of the ignition 
circuit cut-off system.) 



3-3 



INSTRUMENT AND CONTROL FUNCTIONS 




1 . Shift pedal 

EAU00157 

Shift pedal 

This motorcycle is equipped with a con- 
stant-mesh 5-speed transmission. 
The shift pedal is located on the left 
side of the engine and is used in com- 
bination with the clutch when shifting. 



1 . Front brake lever 

EAU00158 

Front brake lever 

The front brake lever is located on the 
right handlebar. Pull it toward the han- 
dlebar to apply the front brake. 



1 . Rear brake pedal 

EAU00162 

Rear brake pedal 

The rear brake pedal is on the right 
side of the motorcycle. Press down on 
the brake pedal to apply the rear brake. 



3-4 



INSTRUMENT AND CONTROL FUNCTIONS 




1. Open 

EAU00167 

Fuel tank cap 
To open 

Insert the key and turn it 1/4 turn clock- 
wise. The lock will be released and the 
cap can be opened. 

To close 

Push the tank cap into position with the 
key inserted. To remove the key, turn it 
counterclockwise to the original posi- 
tion. 



NOTE: 

This tank cap cannot be closed unless 
the key is in the lock. The key cannot 
be removed if the cap is not locked 
properly. 



A WARNING 



Be sure the cap is properly installed 
and locked in place before riding the 
motorcycle. 




1. Filler tube 

2. Fuel level 

EAU01183 

Fuel 

Make sure there is sufficient fuel in the 
tank. Fill the fuel tank to the bottom of 
the filler tube as shown in the illustra- 
tion. 



A WARNING 



Do not overfill the fuel tank. Avoid 
spilling fuel on the hot engine. Do 
not fill the fuel tank above the bot- 
tom of the filler tube or it may over- 
flow when the fuel heats up later and 
expands. 



3-5 



INSTRUMENT AND CONTROL FUNCTIONS 



CAUTION- 



Always wipe off spilled fuel immedi- 
ately with a dry and clean soft cloth. 
Fuel may deteriorate painted surfac- 
es or plastic parts. 



Recommended fuel: 

UNLEADED FUEL 
Fuel tank capacity: 
Total: 

1 3.5 L (3.0 Imp gal, 3.6 US gal) 
Reserve: 

2.5 L (0.5 Imp gal, 0.7 US gal) 



Your Yamaha engine has been de- 
signed to use regular unleaded gaso- 
line with a pump octane number 
([R+M]/2) of 86 or higher, or research 
octane number of 91 or higher. If 
knocking or pinging occurs, use a dif- 
ferent brand of gasoline or premium 
unleaded fuel. Unleaded fuel will give 
you longer spark plug life and reduced 
maintenance cost. If unleaded gasoline 
is not available, then leaded regular 
gasoline can be used. 

Gasohol 

There are two types of gasohol; gaso- 
hol containing ethanol and that contain- 
ing methanol. Gasohol containing 
ethanol can be used if ethanol content 
does not exceed 10%. Gasohol con- 
taining methanol is not recommended 
by Yamaha because it can cause fuel 
system damage or vehicle perfor- 
mance problems. 




1 . Starter (choke) " |\| " 

EAU02976 

Starter (choke) "|\|" 

Starting a cold engine requires a richer 
air-fuel mixture. A separate starter cir- 
cuit supplies this mixture. 
Move in direction ® to turn on the 
starter (choke). 

Move in direction © to turn off the 
starter (choke). 



3-6 



INSTRUMENT AND CONTROL FUNCTIONS 




1 . Steering lock 

EAU02934 

Steering lock 
To lock the steering 

Turn the handlebars all the way to the 
right and open the steering lock cover. 
Insert the key and turn it 1/8 turn coun- 
terclockwise. Then, push the key in 
while turning the handlebars slightly to 
the left and turn the key 1/8 turn clock- 
wise. 

Check that the steering is locked, re- 
move the key and close the lock cover. 

To unlock the steering 

Insert the key, push it in and turn it 
1/8 turn counterclockwise so that it 
moves out. Then, release and remove 
the key. 



1 . Seat lock 

2. Open 

EAU02940 

Seats 

Passenger seat 

To remove 

Insert the key in the seat lock and turn it 

clockwise. 



1. Projection 

2. Seat holder 

To install 

Insert the projection on the rear of the 
seat into the seat holder, and then push 
down on the seat. 



3-7 



INSTRUMENT AND CONTROL FUNCTIONS 




1. Bolt (x 2) 

Rider seat 

To remove 

Remove the passenger seat and then 

remove the two rider seat bolts. 



Seat holder (x 2) 
Projection (x 2) 



To install 

Insert the projections on the front of the 

seat into the seat holders and tighten 

the bolts. Then, install the passenger 

seat. 

NOTE: 

Make sure that the seats are securely 
fitted. 



1. Open 

EAU00260 

Helmet holder 

To open the helmet holder, insert the 
key in the lock and turn it as shown. To 
lock the helmet holder, replace the 
holder in its original position. 



44 WARNING 



Never ride with a helmet in the hel- 
met holder. The helmet may hit ob- 
jects, causing loss of control and 
possibly an accident. 



3-8 



INSTRUMENT AND CONTROL FUNCTIONS 




1 . Spring preload adjusting ring 

2. Position indicator 

EAU00300 

Rear shock absorber 
adjustment 

Each shock absorber is equipped with 
a spring preload adjusting ring. Adjust 
spring preload as follows. Turn the ad- 
justing ring in direction @ to increase 
spring preload and in direction © to de- 
crease spring preload. Make sure that 
the appropriate notch in the adjusting 
ring is aligned with the position indica- 
tor on the rear shock absorber. 



^-\^ 


Soft 


Standard 


Hard 


Adjusting 
position 


1 


2 


3 


4 


5 



f ilW l zMWJ 



Always adjust each shock absorber 
to the same setting. Uneven adjust- 
ment can cause poor handling and 
loss of stability. 



Sidestand 

This model is equipped with an ignition 
circuit cut-off system. The motorcycle 
must not be ridden when the sidestand 
is down. The sidestand is located on 
the left side of the frame. (Refer to 
page 5-1 for an explanation of this sys- 
tem.) 



A WARNING 



This motorcycle must not be operat- 
ed with the sidestand in the down po- 
sition. If the stand is not properly 
retracted, it could contact the ground 
and distract the operator, resulting in 
a possible loss of control. Yamaha 
has designed into this motorcycle a 
lockout system to assist the operator 
in fulfilling the responsibility of re- 
tracting the sidestand. Please check 
carefully the operating instructions 
listed below and if there is any indi- 
cation of a malfunction, return the 
motorcycle to a Yamaha dealer im- 
mediately for repair. 



3-9 



INSTRUMENT AND CONTROL FUNCTIONS 



Sidestand/clutch switch 
operation check 

Check the operation of the sidestand 
switch and clutch switch against the in- 
formation below. 



TURN THE MAIN SWITCH TO "ON" 
AND THE ENGINE STOP SWITCH TO 
"RUN". 



TRANSMISSION IS IN GEAR AND 
SIDESTAND IS UP. 



PULL IN CLUTCH LEVER AND 
PUSH THE START SWITCH. 



ENGINE WILL START. 



SIDESTAND IS DOWN. 


" 


ENGINE WILL STALL. 


" 


SIDESTAND SWITCH IS OK. 



A WARNING 



If improper operation is noted, con- 
sult a Yamaha dealer immediately. 



CLUTCH SWITCH IS OK. 



3-10 



PRE-OPERATION CHECKS 



Pre-operation check list 4-1 



PRE-OPERATION CHECKS 



Owners are personally responsible for their vehicle's condition. Your motorcycle's vital functions can start to deteriorate 
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or 
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in- 
spection, you check the following points before each ride. 



PRE-OPERATION CHECK LIST 



ITEM 


CHECKS 


PAGE 


Front brake 


• Check operation, free play, fluid level and vehicle for fluid leakage. 

• Fill with DOT 4 (or DOT 3) brake fluid if necessary. 


6-19-6-22 


Rear brake 


• Check operation, condition and free play. 

• Adjust if necessary. 


Clutch 


• Check operation, condition and clutch lever free play. 

• Adjust if necessary. 


6-18 


Engine oil 


• Check engine oil level. 

• Fill with oil if necessary. 


6-9-6-11 


Final gear oil 


• Check vehicle for leakage. 


6-11 -6-12 


Throttle grip and housing 


• Check for smooth operation. 

• Lubricate if necessary. 


6-14,6-23 


Battery 


• Check fluid level. 

• Fill with distilled water if necessary. 


6-26 - 6-27 


Lights, signals and 
switches 


• Check for proper operation. 


6-29 - 6-30 


Wheels and tires 


• Check tire pressure, wear, damage and spoke tightness. 

• Tighten spokes if nesessary. 


6-15-6-17 


Chassis fasteners 


• Make sure that all nuts, bolts and screws are properly tightened. 

• Tighten if necessary. 


— 



4-1 



PRE-OPERATION CHECKS 



ITEM 


CHECKS 


PAGE 


Control and meter cables 


• Check for smooth operation. 

• Lubricate if necessary. 


6-23 


Brake and shift pedal 
shafts 


• Check for smooth operation. 

• Lubricate if necessary. 


6-23 


Brake and clutch lever 
pivots 


• Check for smooth operation. 

• Lubricate if necessary. 


6-24 


Sidestand pivot 


• Check for smooth operation. 

• Lubricate if necessary. 


6-24 


Fuel 


• Check fuel level. 

• Fill with fuel if necessary. 


3-5 - 3-6 



NOTE: 

Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accom- 
plished in a very short time; and the added safety it assures is more than worth the time involved. 



A WARNING 



• The engine, exhaust pipes, and mufflers will be very hot after the engine has been run. Be careful not to touch 
them or to allow any clothing item to contact them during inspection or repair. 

• If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repaired before op- 
erating the motorcycle. 



4-2 



OPERATION AND IMPORTANT RIDING POINTS 



Starting and warming up a cold engine 5-1 

Starting a warm engine 5-4 

Shifting 5-4 

To start out and accelerate 5-5 

To decelerate 5-5 

Recommended shift points 5-5 

Engine break-in 5-6 

Parking 5-7 



OPERATION AND IMPORTANT RIDING POINTS 



A WARNING 



CAUTION: 



Before riding this motorcycle, 
become thoroughly familiar 
with all operating controls and 
their functions. Consult a 
Yamaha dealer regarding any 
control or function that you do 
not thoroughly understand. 
Never start your engine or let it 
run for any length of time in a 
closed area. The exhaust fumes 
are poisonous and can cause 
loss of consciousness and 
death within a short time. Al- 
ways operate your motorcycle 
in an area with adequate ventila- 
tion. 

Before starting out, always be 
sure the sidestand is up. Failure 
to retract the sidestand com- 
pletely can result in a serious 
accident when you try to turn a 
corner. 



Be careful where you store per- 
sonal items on the motorcycle. 
Avoid blocking the air cleaner 
intake or performance will suf- 
fer. 

Be careful not to put anything 
near the battery and its termi- 
nals. Electrical failure and acid 
corrosion may result. 



Starting and warming up a 
cold engine 

NOTE: 

This motorcycle is equipped with an ig- 
nition circuit cut-off system. 
The engine can be started only under 
one of the following conditions: 

• The transmission is in neutral. 

• The sidestand is up, the transmis- 
sion is in gear and the clutch is dis- 
engaged. 

The motorcycle must not be ridden 
when the sidestand is down. 



A WARNING 



Before going through the following 
steps, check the function of the 
sidestand switch and clutch switch. 
(Refer to page 3-10.) 



5-1 



OPERATION AND IMPORTANT RIDING POINTS 



TURN THE MAIN SWITCH TO "ON" AND THE 
ENGINE STOP SWITCH TO "RUN". 



IF TRANSMISSION IS IN NEUTRAL AND 
SIDESTAND IS DOWN, 



IF TRANSMISSION IS IN GEAR AND 
SIDESTAND IS UP, 



PUSH THE START SWITCH. 
ENGINE WILL START. 



PULL IN THE CLUTCH LEVER AND PUSH THE 
START SWITCH. ENGINE WILL START. 



RETRACT SIDESTAND AND PUT 
TRANSMISSION IN GEAR. 



MOTORCYCLE CAN BE RIDDEN. 



MOTORCYCLE CAN BE RIDDEN. 



5-2 



OPERATION AND IMPORTANT RIDING POINTS 



1 . Turn the main switch to "ON" and 
the engine stop switch to "RUN". 

2. Shift the transmission into neutral. 

NOTE: 

When the transmission is in neutral, the 
neutral indicator light should be on. If 
the light does not come on, ask a 
Yamaha dealer to inspect it. 

3. Turn on the starter (choke) and 
completely close the throttle grip. 

4. Start the engine by pushing the 
start switch. 

NOTE: 

If the engine fails to start, release the 
start switch, wait a few seconds, then 
try again. Each attempt should be as 
short as possible to preserve the bat- 
tery. Do not crank the engine more 
than 1 seconds on any one attempt. 



5. After starting the engine, move the 
starter (choke) back to the halfway 
position. 

NOTE: 

For maximum engine life, always warm 
up the engine before starting off. Never 
accelerate hard with a cold engine. 

6. After warming up the engine, turn 
off the starter (choke) completely. 



NOTE: 

• The engine is warm when it re- 
sponds normally to the throttle 
with the starter turned off. To avoid 
the possibility of excessive ex- 
haust emissions, never leave the 
starter circuit on longer than nec- 
essary. The length of time the 
starter is needed depends upon 
the ambient temperature. Warm 
ambient temperatures (above 
10°C/50T) require about 7 sec- 
onds of starter use. Cold ambient 
temperatures (below 10°C/50°F) 
require about 35 seconds with the 
starter turned on, then about 
2.5 minutes with the starter in the 
halfway position. 

• For maximum engine life, always 
warm up the engine before start- 
ing off. Never accelerate hard with 
a cold engine. 



5-3 



OPERATION AND IMPORTANT RIDING POINTS 



Starting a warm engine 

The starter (choke) is not required 
when the engine is warm. 

EC000046 

CAUTION: 



See the "Engine break-in" section 
prior to operating the motorcycle for 
the first time. 



\+' ? 




ZaS^W^ 


2 J^L 

1 Y 




M Y^~f^ 


^ 


i © K 


1 


^ 





CAUTION: 



1. Shift pedal 
N. Neutral 

EAU00423 

Shifting 

The transmission lets you control the 
amount of power you have available at 
a given speed for starting, accelerating, 
climbing hills, etc. The use of the shift 
pedal is shown in the illustration. 
To shift into neutral, depress the shift 
pedal repeatedly until it reaches the 
end of its travel, then raise the pedal 
slightly. 



Do not coast for long periods 
with the engine off, and do not 
tow the motorcycle a long dis- 
tance. Even with gears in neu- 
tral, the transmission is only 
properly lubricated when the 
engine is running. Inadequate 
lubrication may damage the 
transmission. 

Always use the clutch when 
changing gears. The engine, 
transmission, and driveline are 
not designed to withstand the 
shock of forced shifting and 
can be damaged by shifting 
without using the clutch. 



5-4 



OPERATION AND IMPORTANT RIDING POINTS 



To start out and accelerate 

1 . Pull the clutch lever to disengage 
the clutch. 

2. Shift into first gear. The neutral in- 
dicator light should go out. 

3. Open the throttle gradually, and at 
the same time, release the clutch 
lever slowly. 

4. At the recommended shift points 
shown in the table, close the throt- 
tle, and at the same time, quickly 
pull in the clutch lever. 

5. Shift into second gear. (Be careful 
not to shift into neutral.) 

6. Open the throttle part way and 
gradually release the clutch lever. 

7. Follow the same procedure when 
shifting to the next higher gear. 
Always shift gears at the recom- 
mended shift points. 



To decelerate 

1 . Apply both the front and the rear 
brakes at the same time to slow 
the motorcycle. 

2. When the motorcycle reaches 
20 km/h (12.5 mi/h), shift into first 
gear. Any time the engine is about 
to stall or runs very roughly, pull in 
the clutch and use the brakes to 
stop. 

3. When the motorcycle is almost 
completely stopped, shift into neu- 
tral. The neutral indicator light 
should come on. 



Recommended shift points 



\^ 


Acceleration 


Deceleration 


^-. 


shift point 


shift point 


\ 


km/h (mi/h) 


km/h (mi/h) 


1st -> 2nd 


16(9.9) 


20(12.5) 


2nd -> 3rd 


24(14.9) 


20(12.5) 


3rd -> 4th 


32(19.9) 


20 (12.5) 


4th -> 5th 


40 (24.9) 


20(12.5) 



5-5 



OPERATION AND IMPORTANT RIDING POINTS 



Engine break-in 

There is never a more important period 
in the life of your motorcycle than the 
period between zero and 1,000 km 
(600 mi). For this reason we ask that 
you carefully read the following materi- 
al. Because the engine is brand new, 
you must not put an excessive load on 
it for the first 1 ,000 km (600 mi). The 
various parts in the engine wear and 
polish themselves to the correct oper- 
ating clearances. During this period, 
prolonged full throttle operation, or any 
condition which might result in exces- 
sive heating of the engine, must be 
avoided. 



0-150 km (0-90 mi) 

Avoid operation above 1/3 throttle. 
Stop the engine and let it cool for 5 to 
10 minutes after every hour of opera- 
tion. Vary the speed of the motorcycle 
from time to time. Do not operate it at 
one set throttle position. 

150 -500 km (90 -300 mi) 

Avoid prolonged operation above 
1/2 throttle. Rev the motorcycle freely 
through the gears, but do not use full 
throttle at any time. 

500 ~ 1,000 km (300 - 600 mi) 

Avoid cruising speeds in excess of 
3/4 throttle. 



1,000 km (600 mi) and beyond 

Avoid prolonged full-throttle operation. 
Vary speed occasionally. 

EC0O0O49 

CAUTION: 



If any engine trouble should occur 
during the break-in period, consult a 
Yamaha dealer immediately. 



CAUTION: 



After 1 ,000 km (600 mi) of operation, 
be sure to replace the engine oil, oil 
filter and final gear oil. 



5-6 



OPERATION AND IMPORTANT RIDING POINTS 



Parking 

When parking the motorcycle, stop the 
engine and remove the ignition key. 



A WARNING 



The exhaust system is hot. Park the 
motorcycle in a place where pedes- 
trians or children are not likely to 
touch the motorcycle. Do not park 
the motorcycle on a slope or soft 
ground; the motorcycle may over- 
turn. 



5-7 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Periodic maintenance 6-1 

Toolkit 6-1 

Periodic maintenance chart for emission 

control system 6-3 

General maintenance and lubrication chart 6-4 

Spark plugs 6-7 

Canister (for California only) 6-8 

Engine oil 6-9 

Final gear oil 6-11 

Air filter 6-12 

Carburetor adjustment 6-14 

Throttle cable free play inspection 6-14 

Valve clearance adjustment 6-15 

Tires 6-15 

Wheels 6-17 

Accessories or replacement parts 6-17 

Clutch lever free play adjustment 6-18 

Front brake lever free play adjustment 6-19 

Rear brake pedal height and free play 

adjustment 6-19 



Brake light switch adjustment 6-20 

Checking the front brake pads and 

rear brake shoes 6-21 

Inspecting the brake fluid level 6-21 

Brake fluid replacement 6-22 

Cable inspection and lubrication 6-23 

Throttle cable and grip lubrication 6-23 

Brake and shift pedal lubrication 6-23 

Brake and clutch lever lubrication 6-24 

Sidestand lubrication 6-24 

Rear suspension lubrication 6-24 

Front fork inspection 6-25 

Steering inspection 6-25 

Wheel bearings 6-26 

Battery 6-26 

Fuse replacement 6-28 

Headlight bulb replacement 6-29 

Turn signal and taillight bulb replacement 6-30 

Troubleshooting 6-31 

Troubleshooting chart 6-32 



PERIODIC MAINTENANCE AND MINOR REPAIR 



EAU01790 

Periodic inspection, adjustment, and 
lubrication will keep your motorcycle in 
the safest and most efficient condition 
possible. Safety is an obligation of the 
motorcycle owner. The most important 
points of motorcycle inspection, adjust- 
ment, and lubrication are explained in 
the following pages. 
Maintenance, replacement, or repair 
of the emission control devices and 
systems may be performed by any 
repair establishment or individual 
that is certified (if applicable). 



A WARNING 



If you are not familiar with motor- 
cycle service, this work should be 
done by a Yamaha dealer. 



EAU00467 

PERIODIC MAINTENANCE 

PROPER PERIODIC MAINTENANCE 
OF YOUR MOTORCYCLE IS IMPOR- 
TANT IN ORDER TO ENJOY LONG, 
PLEASURABLE SERVICE. ESPE- 
CIALLY IMPORTANT ARE THE 
MAINTENANCE SERVICES RELAT- 
ED TO EMISSIONS CONTROL. 
THESE CONTROLS NOT ONLY 
FUNCTION TO ENSURE CLEANER 
AIR BUT ARE ALSO VITAL TO PROP- 
ER ENGINE OPERATION AND MAXI- 
MUM PERFORMANCE. IN THE 
FOLLOWING TABLES OF PERIODIC 
MAINTENANCE, THE SERVICES RE- 
LATED TO EMISSIONS CONTROL 
ARE GROUPED SEPARATELY. 
THESE SERVICES REQUIRE SPE- 
CIALIZED DATA, KNOWLEDGE, AND 
EQUIPMENT. YAMAHA DEALERS 
ARE TRAINED AND EQUIPPED TO 
PERFORM THESE PARTICULAR 
SERVICES. 




1 . Tool kit 

EAU00468 

Tool kit 

The service information included in this 
manual is intended to provide you, the 
owner, with the necessary information 
for completing some of your own pre- 
ventive maintenance and minor re- 
pairs. The tools provided in the owner's 
tool kit are to assist you in the perfor- 
mance of periodic maintenance. How- 
ever, some other tools such as a torque 
wrench are also necessary to perform 
the maintenance correctly. 



6-1 



PERIODIC MAINTENANCE AND MINOR REPAIR 



NOTE:_ 



If you do not have necessary tools re- 
quired during a service operation, take 
your motorcycle to a Yamaha dealer 
for service. 



A WARNING 



Modifications to this motorcycle not 
approved by Yamaha may cause 
loss of performance, excessive 
emissions, and render it unsafe for 
use. Consult a Yamaha dealer be- 
fore attempting any changes. 



6-2 



PERIODIC MAINTENANCE AND MINOR REPAIR 



PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM 







ITEM 


ROUTINE 


INITIAL 


ODOMETER READINGS 


No. 


600 mi 
(1,000 km) 

or 
1 month 


4,000 mi 
(7,000 km) 

or 
6 months 


8,000 mi 
(13,000 km) 

or 
12 months 


12,000 mi 
(19,000 km) 

or 
18 months 


16,000 mi 
(25,000 km) 

or 
24 months 


20,000 mi 
(31,000 km) 

or 
30 months 


1 


* 


Valve clearance 


• Check and adjust valve clearance when 
engine is cold. 


V 


V 


V 


V 


V 


V 


2 




Spark plugs 


• Check condition. 

• Adjust gap and clean. 

• Replace at 8,000 mi (13,000 km) 
or 12 months and thereafter 

every 8,000 mi (13,000 km) or 12 months. 




V 


Replace 


V 


Replace 


V 


3 


• 


Crankcase ventilation 
system 


• Check ventilation hose for cracks or damage. 

• Replace if necessary. 




V 


V 


V 


V 


V 


4 


* 


Fuel line 


• Check fuel hose and vacuum pipe for cracks 
or damage. 

• Replace if necessary. 




V 


V 


V 


V 


V 


5 


• 


Exhaust system 


• Check for leakage. 

• Retighten if necessary. 

• Replace gasket(s) if necessary. 




V 


V 


V 


V 


V 


6 


• 


Carburetor 
Synchronization 


• Adjust synchronization of carburetors. 


V 


V 


V 


V 


V 


V 


7 


* 


Idle speed 


• Check and adjust engine idle speed. 

• Adjust cable free play. 




V 


V 


V 


V 


V 


8 


• 


Evaporative emission 
control system** 


• Check control system for damage. 

• Replace if necessary. 








V 




V 



* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. 
** California only 



6-3 



PERIODIC MAINTENANCE AND MINOR REPAIR 



GENERAL MAINTENANCE AND LUBRICATION CHART 







ITEM 


ROUTINE 


TYPE 


INITIAL 


ODOMETER READINGS 


No. 


600 mi 

(1,000 km) 

or 

1 month 


4,000 mi 
(7,000 km) 

or 
6 months 


8,000 mi 
(13,000 km) 

or 
12 months 


12,000 mi 
(19,000 km) 

or 
18 months 


16,000 mi 
(25,000 km) 

or 
24 months 


20,000 mi 
(31,000 km) 

or 
30 months 


1 




Engine oil 


• Warm-up engine 
before draining. 


See page 6-9. 


V 


V 


V 


V 


V 


V 


2 


* 


Oil filter 


• Replace. 


- 


V 




V 




V 




3 


• 


Air filter 


• Clean with compressed 
air. 

• Replace if necessary. 


- 




V 


V 


V 


-1 


V 


4 


* 


Brake system 


• Adjust free play. 

• Replace pads if 
necessary. (Front) 

• Replace shoes if 
necessary. (Rear) 


- 


V 


V 


V 


V 


V 


V 


5 


* 


Clutch 


• Adjust free play. 


- 


V 


V 


V 


V 


V 


V 


6 


• 


Final gear oil 


• Check oil level and 
leakage. 

• Replace every 
16,000 mi (25,000 km) 
or 24 months. 


SAE 80 API GL-4 hypoid 
gear oil 


Replace 




Check 




V 




7 




Control and meter 
cable 


• Apply chain lube 
thoroughly. 


Yamaha chain and cable 
lube or SAE 10W30 
motor oil 


V 


V 


V 


V 


V 


V 


8 


* 


Swingarm pivot 
bearing 


• Check bearing 
assembly for 
looseness. 

• Moderately repack 
every 16,000 mi 
(25,000 km). 


Molybdenum disulfide 
grease 










Repack 




9 




Brake/clutch lever 
pivot shaft 


• Apply chain lube lightly. 


Yamaha chain and cable 
lubeorSAE10W30 
motor oil 




V 


V 


V 


V 


V 



6-4 



PERIODIC MAINTENANCE AND MINOR REPAIR 







ITEM 


ROUTINE 


TYPE 


INITIAL 


ODOMETER READINGS 


No. 


600 mi 
(1,000 km) 

or 
1 month 


4,000 mi 
(7,000 km) 

or 
6 months 


8,000 mi 
(13,000 km) 

or 
12 months 


12,000 mi 
(19,000 km) 

or 
18 months 


16,000 mi 
(25,000 km) 

or 
24 months 


20,000 mi 
(31,000 km) 

or 
30 months 


10 


* 


Brake pedal and 
shift pedal shaft 


• Lubricate. 

• Apply chain lube lightly. 


Yamaha chain and cable 
lubeorSAE 10W30 
motor oil 




V 


V 


V 


V 


V 


11 


* 


Sidestand pivot 


• Check operation and 
lubricate. 

• Apply chain lube lightly. 


Yamaha chain and cable 
lubeorSAE10W30 

motor oil 




V 


V 


V 


V 


V 


12 


• 


Front fork 


• Check operation and 
leakage. 


- 




V 


V 


V 


V 


V 


13 


* 


Steering bearings 


• Check bearing 
assembly for 
looseness. 

• Moderately repack 
every 16,000 mi 
(25,000 km). 


Lithium soap base 
grease 




V 


V 


V 


Repack 


V 


14 


* 


Wheel bearings 


• Check bearing for 
smooth rotation. 


- 




V 


V 


V 


V 


V 


15 




Battery 


• Check specific gravity 
and breather pipe for 
proper operation. 


- 




V 


V 


V 


V 


V 


16 


« 


Sidestand switch 


• Check and clean or 
replace if necessary. 


- 


V 


V 


V 


V 


V 


V 



' Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. 



NOTE: 



For odometer readings or time periods higher than 20,000 mi (31 ,000 km) or 30 months, repeat the same maintenance as 
listed in the chart from the 4,000 mi (7,000 km) or 6 month interval. 



6-5 



PERIODIC MAINTENANCE AND MINOR REPAIR 



NOTE: 

• The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 

• Hydraulic brake system 

• When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regularly 
and fill as required. 

• Replace the oil seals on the inner parts of the master cylinder and caliper every two years. 

• Replace the brake hoses every four years or if cracked or damaged. 



6-6 



PERIODIC MAINTENANCE AND MINOR REPAIR 



i^S 


«fmM 






— x£_h_©j | 





1 . Cylinder head cover 

2. Screw (x 2) 

EAU01486 

Spark plugs 
Removal 

1. Remove the rear right and front 
left cylinder head covers by re- 
moving the screws. 

2. Remove the spark plug caps. 




1 . Spark plug wrench 

3. Use the spark plug wrench in the 
tool kit to remove the spark plugs 
as shown. 

Inspection 

The spark plug is an important engine 
component and is easy to inspect. The 
condition of the spark plug can indicate 
the condition of the engine. Normally, 
all spark plugs from the same engine 
should have the same color on the 
white insulator around the center elec- 
trode. The ideal color at this point is a 
medium-to-light tan color for a motor- 
cycle that is being ridden normally. If 
one spark plug shows a distinctly differ- 



ent color, there could be something 
wrong with the engine. Do not attempt 
to diagnose such problems yourself. In- 
stead, take the motorcycle to a 
Yamaha dealer. You should periodical- 
ly remove and inspect the spark plugs 
because heat and deposits will cause 
any spark plug to slowly break down 
and erode. If electrode erosion be- 
comes excessive, or if carbon and oth- 
er deposits are excessive, you should 
replace the spark plug with the speci- 
fied plug. 



Specified spark plug: 
BP7ES (NGK) or 
W22EP-U (DENSO) 



6-7 



PERIODIC MAINTENANCE AND MINOR REPAIR 




a. Spark plug gap 

Installation 

1 . Measure the electrode gap with a 
wire thickness gauge and, if nec- 
essary, adjust the gap to specifica- 
tion. 



Spark plug gap: 

0.7 - 0.8 mm (0.028 ~ 0.031 in) 



2. Clean the gasket surface. Wipe off 
any grime from the threads. 

3. Install the spark plug and tighten it 
to the specified torque. 



Tightening torque: 
Spark plug: 

20 Nm (2.0 mkg, 14 ft-lb) 



NOTE: 

If a torque wrench is not available when 
you are installing a spark plug, a good 
estimate of the correct torque is 1/4 to 
1/2 turn past finger tight. Have the 
spark plug tightened to the specified 
torque as soon as possible. 

4. Install the spark plug caps, the cyl- 
inder head covers and the screws. 



EMMISION HOSE ROUTING 
Carburetor From 

O fuel tank 



U Canister 
To atmosphere 



Canister (for California only) 

This model is equipped with a canister 
to prevent the discharging of fuel vapor 
into the atmosphere. Before using this 
motorcycle, be sure to check the fol- 
lowing: 

• Check each hose connection. 

• Check each hose and canister for 
cracks or damage. Replace if 
damaged. 

• Make sure the canister breather is 
not blocked. Clean it if necessary. 



6-8 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1 . Oil level window 

2. Maximum level mark 

3. Minimum level mark 

EAU02942 

Engine oil 

Oil level inspection 

1. Place the motorcycle on a level 
place and hold it in an upright posi- 
tion. Warm up the engine for sev- 
eral minutes. 

NOTE: 

Be sure the motorcycle is positioned 
straight up when checking the oil level. 
A slight tilt toward the side can result in 
false readings. 



2. With the engine stopped, check 
the oil level through the level win- 
dow located at the lower part of 
the left side crankcase cover. 

NOTE: 

Wait a few minutes until the oil level 
settles before checking. 

3. The oil level should be between 
the maximum and minimum 
marks. If the level is low, fill the en- 
gine with sufficient oil to the speci- 
fied level. 




1 . Engine oil filler cap 

Engine oil and oil filter element 
replacement 

1 . Warm up the engine for a few min- 
utes. 

2. Stop the engine. Place an oil pan 
under the engine and remove the 
oil filler cap. 



6-9 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1. Engine oil drain bolt 

3. Remove the drain bolt and drain 
the oil. 



1 . Oil filter cover 

2. Bolt (x 3) 

4. Remove the oil filter bolts, oil filter 
and O-ring. 

5. Install the drain bolt and tighten it 
to the specified torque. 



Tightening torque: 
Drain bolt: 

43 Nm (4.3 m-kg, 31 ft-lb) 



6. Install the new oil filter, new O-ring 
and the filter cover. Then tighten 
the oil filter bolts to the specified 
torque. 



Tightening torque: 
Oil filter bolts: 

10 Nm (1.0 m-kg, 7.2 ft-lb) 



1. O-ring 

2. Oil filter element 

NOTE: 



Make sure the O-ring is seated proper- 
ly^ 

7. Fill the engine with oil. Install the 
oil filler cap and tighten it. 



Recommended oil: 

See page 8-1 . 
Oil quantity: 
Total amount: 

3.2 L (2.8 Imp qt, 3.4 US qt) 
Periodic oil change: 

2.6 L (2.3 Imp qt, 2.8 US qt) 
With oil filter replacement: 
2.8 L (2.5 Imp qt, 3.0 US qt) 



6-10 



PERIODIC MAINTENANCE AND MINOR REPAIR 



CAUTION: 



Do not put in any chemical addi- 
tives. Engine oil also lubricates 
the clutch and additives could 
cause clutch slippage. 
Be sure no foreign material en- 
ters the crankcase. 

Start the engine and warm it up for 
a few minutes. While warming up, 
check for oil leakage. If oil leakage 
is found, stop the engine immedi- 
ately and check for the cause. 




1 . Final gear oil drain bolt 

2. Final gear oil 

3. Final gear oil filler bolt 

4. Correct level 

Final gear oil 



A WARNING 



Do not let foreign material enter the 
final gear case. Be sure oil does not 
get on the tire or wheel. 

Oil level inspection 

1. Place the motorcycle on a level 
place and hold it in an upright posi- 
tion. The engine should be cool at 
ambient temperature. 



2. Remove the oil filler bolt and 
check the oil level. The oil level 
should be at the brim of the filler 
hole. Add the recommended oil if 
necessary. 

Oil replacement 

1. Place an oil pan under the final 
gear case. 

2. Remove the oil filler bolt and drain 
bolt to drain the oil. 

3. Install and tighten the drain bolt to 
the specified torque. 



Tightening torque: 
Drain bolt: 

23 Nm (2.3 m-kg, 17 ft-lb) 



Fill the gear case to the brim of the 
filler hole with the recommended 
oil. 



6-11 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Final gear case capacity: 

0.19 L (0.17 Imp qt, 0.20 US qt) 

Recommended oil: 

SAE 80 API GL-4 Hypoid gear oil 
If desired, an SAE 80W90 hypoid 
gear oil may be used for all 
conditions. 



NOTE: 

"GL-4" is a quality and additive rating. 
Hypoid gear oils rated "GL-5" or "GL-6" 
may also be used. 

5. Install and tighten the filler bolt to 
the specified torque. 



Tightening torque: 
Oil filler bolt: 

23 Nm (2.3 m-kg, 17ftlb) 



6. After replacing the final gear oil, be 
sure to check for oil leakage. 




1 . Fuel tank 

2. Bolt (x 3) 

EAU02998 

Air filter 

The air filter should be cleaned at the 
specified intervals. It should be cleaned 
more frequently if you are riding in un- 
usually wet or dusty areas. 

1 . Remove the seats. (See page 3-7 
for seat removal and installation 
procedures.) 

2. Remove the fuel tank bolts. 



//_ 




1 


V 




^J2>J 






< &%- r — - 






fc 


2W 




\\ 


h 



1. Screw 

3. Lift the front of the fuel tank up- 
ward and position it away from the 
air filter. (Do not remove the fuel 
tank.) 



44 WARNING 



• Support the fuel tank carefully 
during this procedure. 

• Do not tilt the fuel tank too 
much or pull it too hard be- 
cause the fuel hose connec- 
tions may become loose 
causing fuel leakage. 

4. Remove the air filter case cover 
screw. 



6-12 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1. Air filter case cover 

2. Tab 

3. Holder 

4. Air filter 

5. Slide the air filter case cover so as 
to unhook the tab on the rear of 
the cover from the holder on the 
frame. Then lift the air filter case 
cover upward without removing it. 



6. Pull out the air filter element and 
tap it lightly to remove most of the 
dust and dirt. Blow out the remain- 
ing dirt with compressed air as 
shown. If the air filter element is 
damaged, replace it. 



7. Reassemble by reversing the re- 
moval procedure. 

EC000082 

CAUTION: 



Make sure the air filter is prop- 
erly seated in the air filter case. 
The engine should never be run 
without the air filter installed. 
Excessive piston and/or cylin- 
der wear may result. 



6-13 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1. Washer 

2. Rubber damper 

3. Spacer 



i4 WARNING 



Make sure that the fuel hoses and 
vacuum hose are properly connect- 
ed, in place and not pinched. If a 
hose is damaged, be sure to replace 
it. 



Carburetor adjustment 

The carburetors are important parts of 
the engine and emission control sys- 
tem. Adjusting should be left to a 
Yamaha dealer with the professional 
knowledge, specialized data and 
equipment to do so properly. 




a. Free play 

EAU00635 

Throttle cable free play 
inspection 

There should be a free play of 3 ~ 
5 mm (0.12 ~ 0.20 in) at the throttle 
grip. If the free play is incorrect, ask a 
Yamaha dealer to make this adjust- 
ment. 



CAUTION: 



When reinstalling the fuel tank hold- 
ing bolts, make sure that the wash- 
ers, damper rubbers and spacers 
are positioned properly. 



6-14 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Valve clearance adjustment 

The correct valve clearance changes 
with use, resulting in improper fuel/air 
supply or engine noise. To prevent this, 
the valve clearance must be adjusted 
regularly. This adjustment however, 
should be left to a professional 
Yamaha service technician. 



Tires 

To ensure maximum performance, 
long service, and safe operation, note 
the following: 

Tire air pressure 

Always check and adjust the tire pres- 
sure before operating the motorcycle. 



A WARNING 



Tire inflation pressure should be 
checked and adjusted when the 
temperature of the tire equals the 
ambient air temperature. Tire infla- 
tion pressure must be adjusted ac- 
cording to total weight of cargo, 
rider, passenger, and accessories 
(fairing, saddlebags, etc. if approved 
for this model), and vehicle speed. 



Maximum load* 



Cold tire pressure 



Up to 90 kg (198 lb) 
load* 



90 kg (198 lb) load- 
Maximum load* 



220 kg (485 lb): XV535 
219kg(483lb):XV535C 



Front 



200 kPa 

(2.00 kgf/cm 2 , 

29 psi) 



200 kPa 

(2.00 kgf/cm 2 

29 psi) 



Rear 



225 kPa 

(2.25 kgf/cm 2 , 

33 psi) 



250 kPa 

(2.50 kgf/cm 2 , 

36 psi) 



Load is the total weight of cargo, rider, passenger 
and accessories. 



6-15 



PERIODIC MAINTENANCE AND MINOR REPAIR 



A WARNING 



Proper loading of your motorcycle 
is important for several characteris- 
tics of your motorcycle, such as 
handling, braking, performance and 
safety. Do not carry loosely packed 
items that can shift. Securely pack 
your heaviest items close to the 
center of the motorcycle, and dis- 
tribute the weight evenly from side 
to side. Properly adjust the suspen- 
sion for your load, and check the 
condition and pressure of your tires. 
NEVER OVERLOAD YOUR MOTOR- 
CYCLE. Make sure the total weight 
of the cargo, rider, passenger, and 
accessories (fairing, saddlebags, 
etc. if approved for this model) does 
not exceed the maximum load of the 
motorcycle. Operation of an over- 
loaded motorcycle could cause tire 
damage, an accident, or even injury. 




FRONT 



1 . Side wall 

2. Wear indicator 
a. Tread depth 

Tire inspection 

Always check the tires before operating 
the motorcycle. If a tire tread shows 
crosswise lines (minimum tread depth), 
if the tire has a nail or glass fragments 
in it, or if the side wall is cracked, con- 
tact a Yamaha dealer immediately and 
have the tire replaced. 



Manufacturer 


Size 


Type 


Bridgestone 


3.00-19 49S 


L303A 


Dunlop 


3.00-19 49S 


F14G 



REAR 



Manufacturer 


Size 


Type 


Bridgestone 


140/90-15 M/C 70S 


G508 


Dunlop 


140/90-15 M/C 70S 


K425 



Minimum tire tread 
depth (front and rear) 


1 .0 mm (0.04 in) 



6-16 



PERIODIC MAINTENANCE AND MINOR REPAIR 



A WARNING 



It is dangerous to ride with a 
worn-out tire. When a tire tread 
begins to show lines, have a 
Yamaha dealer replace the tire 
immediately. Brakes, tires, and 
related wheel parts replacement 
should also be left to a Yamaha 
dealer. 

Patching a punctured tube is 
not recommended. If it is abso- 
lutely necessary to do so, use 
great care and replace the tube 
as soon as possible with a good 
quality replacement. 



Wheels 

To ensure maximum performance, 
long service, and safe operation, note 
the following: 

• Always inspect the wheels before 
a ride. Check for cracks, bends or 
warpage of the wheel. Be sure the 
spokes are tight and undamaged. 
If any abnormal condition exists in 
a wheel, consult a Yamaha dealer. 
Do not attempt even small repairs 
to the wheel. If a wheel is de- 
formed or cracked, it must be re- 
placed. 

• Tires and wheels should be bal- 
anced whenever either one is 
changed or replaced. Failure to 
have a wheel balanced can result 
in poor performance, adverse han- 
dling characteristics, and short- 
ened tire life. 

• Ride at moderate speeds after 
changing a tire since the tire sur- 
face must first be broken in for it to 
develop its optimal characteristics. 



Accessories or replacement 
parts 



A WARNING 



This motorcycle is not designed to 
pull a trailer or to be attached to a 
sidecar. The accessories or replace- 
ment parts you choose for your 
motorcycle should be designed spe- 
cifically for it, and they must be se- 
curely mounted to maintain the 
inherent stability of the original de- 
sign. Genuine Yamaha Parts and 
Accessories are designed and test- 
ed to be compatible with your 
motorcycle. Please consider Genu- 
ine Yamaha Parts and Accessories 
before making an accessory pur- 
chase. Use of non-Yamaha-ap- 
proved parts or accessories may 
cause loss of handling stability and 
riding safety. Since Yamaha cannot 
control the quality of parts or acces- 
sories manufactured by other com- 
panies, Yamaha cannot be held 



6-17 



PERIODIC MAINTENANCE AND MINOR REPAIR 



liable for any consequences caused 
by the use of items which have not 
been approved by Yamaha. 




1. Locknut 

2. Adjusting bolt 
c. Free play 

EAU00694 

Clutch lever free play 
adjustment 

The clutch lever free play should be ad- 
justed to 10 ~ 15 mm (0.39 ~ 0.59 in). 

1 . Loosen the locknut at the clutch le- 
ver. 

2. Turn the adjusting bolt at the 
clutch lever in direction ® to in- 
crease free play or in direction © 
to decrease free play. 

3. Tighten the locknut at the clutch 
lever. 



1. Locknut 

2. Adjusting nut 

If the specified free play cannot be ob- 
tained, proceed with the following steps. 

4. Loosen the locknut at the clutch le- 
ver. 

5. Turn the adjusting bolt at the 
clutch lever in direction ® to loos- 
en the cable. 

6. Loosen the locknut at the crank- 
case side. 

7. Turn the adjusting nut at the 
crankcase in direction ® to in- 
crease free play or in direction © 
to decrease free play. 

8. Tighten the locknut at the crank- 
case and the clutch lever. 



6-18 



PERIODIC MAINTENANCE AND MINOR REPAIR 




A WARNING 



1 . Adjusting bolt 

2. Locknut 
c. Free play 

EAU00696 

Front brake lever free play 
adjustment 

The free play at the front brake lever 
should be 2 ~ 5 mm (0.08 ~ 0.20 in). 

1 . Loosen the locknut. 

2. Turn the adjusting bolt in direction 
(D to increase free play or in direc- 
tion © to decrease free play. 

3. After adjusting, tighten the locknut. 



Check the brake lever free play. 
Be sure the brake is working 
properly. 

A soft or spongy feeling in the 
brake lever can indicate the 
presence of air in the brake sys- 
tem. This air must be removed 
by bleeding the brake system 
before the motorcycle is operat- 
ed. Air in the system will cause 
greatly diminished braking ca- 
pability and can result in loss of 
control and an accident. Have a 
Yamaha dealer inspect and 
bleed the system if necessary. 




1. Footrest 

2. Pedal height 
a. Free play 



Rear brake pedal height and 
free play adjustment 



A WARNING 



It is advisable to have a Yamaha 
dealer make this adjustment. 

The brake pedal height should be ad- 
justed before adjusting the brake pedal 
free play. 
Pedal height 

The brake pedal should be positioned 
approximately 38 mm (1.5 in) above 
the top of the footrest. 



6-19 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1 . Adjusting bolt 

2. Locknut 

1 . Loosen the locknut. 

2. Turn the adjusting bolt in direction 
@ to raise pedal height or in direc- 
tion © to lower pedal height. 

3. Tighten the locknut. 



A WARNING 



After adjusting the pedal height, ad- 
just brake pedal free play. 



1 . Adjusting nut 

Free play 

The brake pedal free play should be 
adjusted to 20 ~ 30 mm (0.8 ~ 1 .2 in) at 
the brake pedal end. Turn the adjusting 
nut on the brake rod in direction ® to 
increase free play or in direction © to 
decrease free play. 



1 . Brake light switch 

2. Adjusting nut 

EAU00713 

Brake light switch adjustment 

The rear brake light switch is activated 
by the brake pedal and is properly ad- 
justed when the brake light comes on 
just before braking takes effect. To ad- 
just the rear brake light switch, hold the 
switch body so it does not rotate while 
turning the adjusting nut. Turn the ad- 
justing nut in direction © to make the 
brake light come on earlier. Turn the 
adjusting nut in direction © to make the 
brake light come on later. 



6-20 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1 . Wear indicator groove (x 2) 
a. Wear limit 

EAU00720 

Checking the front brake pads 
and rear brake shoes 



Front brake 

Wear indicator grooves are provided 
on each brake pad. These indicators 
allow checking of brake pad wear with- 
out disassembling the brake. Inspect 
the grooves. If they have almost disap- 
peared, ask a Yamaha dealer to re- 
place the pads. 



1 . Wear limit 

2. Wear indicator 

EAU00727 

Rear brake 

Apply the brake and inspect the wear 

indicator. 

If the indicator reaches the wear limit 

line, ask a Yamaha dealer to replace 

the shoes. 



1. Minimum level mark 

EAU00732 

Inspecting the brake fluid 
level 

Insufficient brake fluid may let air enter 

the brake system, possibly causing the 

brakes to become ineffective. 

Before riding, check that the brake fluid 

is above the minimum level and fill 

when necessary. 

Observe these precautions: 
• When checking the fluid level, 
make sure the top of the master 
cylinder is level by turning the han- 
dlebars. 



6-21 



PERIODIC MAINTENANCE AND MINOR REPAIR 



• Use only the designated quality 
brake fluid. Otherwise, the rubber 
seals may deteriorate, causing 
leakage and poor brake perfor- 
mance. 



Recommended brake fluid: DOT 4 



NOTE: 

If DOT 4 is not available, DOT 3 can be 
used. 

• Refill with the same type of brake 
fluid. Mixing fluids may result in a 
harmful chemical reaction and 
lead to poor brake performance. 

• Be careful that water does not en- 
ter the master cylinder when refill- 
ing. Water will significantly lower 
the boiling point of the fluid and 
may result in vapor lock. 



Brake fluid may deteriorate paint- 
ed surfaces or plastic parts. Al- 
ways clean up spilled fluid 
immediately. 

Have a Yamaha dealer check the 
cause if the brake fluid level goes 
down. 



Brake fluid replacement 

The brake fluid should be replaced only 
by trained Yamaha service personnel. 
Have the Yamaha dealer replace the 
following components during periodic 
maintenance or when they are dam- 
aged or leaking: 

• oil seals (every two years) 

• brake hoses (every four years) 



6-22 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Cable inspection and 
lubrication 



A WARNING 



Damage to the outer housing of ca- 
bles may allow internal rusting and 
cause interference with cable move- 
ment. Replace damaged cables as 
soon as possible to prevent unsafe 
conditions. 

Lubricate the cables and cable ends. If 
a cable does not operate smoothly, ask 
a Yamaha dealer to replace it. 



Recommended lubricant: 

Yamaha Chain and Cable Lube 
orSAE 10W30 motor oil 



Throttle cable and grip 
lubrication 

The throttle twist grip assembly should 
be greased at the time that the cable is 
lubricated, since the grip must be re- 
moved to get at the end of the throttle 
cable. After removing the screws, hold 
the end of the cable up in the air and 
put in several drops of lubricant. With 
the throttle grip disassembled, coat the 
metal surface of the grip assembly with 
a suitable all-purpose grease. 




Brake and shift pedal 
lubrication 

Lubricate the pivoting parts. 



Recommended lubricant: 

Yamaha Chain and Cable Lube 
orSAE 10W30 motor oil 



6-23 



PERIODIC MAINTENANCE AND MINOR REPAIR 




Brake and clutch lever 
lubrication 

Lubricate the pivoting parts. 



Recommended lubricant: 

Yamaha Chain and Cable Lube 
orSAE 10W30 motor oil 



Sidestand lubrication 

Lubricate the sidestand pivoting point 
and metal-to-metal contact surfaces. 
Check that the sidestand moves up 
and down smoothly. 



Recommended lubricant: 

Yamaha Chain and Cable Lube 
orSAE 10W30 motor oil 



Rear suspension lubrication 

Lubricate the pivoting parts. 



Recommended lubricant: 

Molybdenum disulfide grease 



A WARNING 



If the sidestand does not move 
smoothly, consult a Yamaha dealer. 



6-24 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Front fork inspection 
Visual check 



A WARNING 



Securely support the motorcycle so 
there is no danger of it falling over. 

Check for scratches or damage on the 
inner tube and excessive oil leakage 
from the front fork. 




Operation check 

1. Place the motorcycle on a level 
place. 

Hold the motorcycle in an upright 
position and apply the front brake. 
Push down hard on the handle- 
bars several times and check if the 
fork rebounds smoothly. 



2. 



3. 



CAUTION: 



If any damage or unsmooth move- 
ment is found with the front fork, 
consult a Yamaha dealer. 



Steering inspection 

Periodically inspect the condition of the 
steering. Worn out or loose steering 
bearings may be dangerous. Place a 
stand under the engine to raise the 
front wheel off the ground. Hold the 
lower end of the front forks and try to 
move them forward and backward. If 
any free play can be felt, ask a Yamaha 
dealer to inspect and adjust the steer- 
ing. Inspection is easier if the front 
wheel is removed. 



A WARNING 



Securely support the motorcycle so 
there is no danger of it falling over. 



6-25 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Wheel bearings 

If there is play in the front or rear wheel 
hub or if the wheel does not turn 
smoothly, have a Yamaha dealer in- 
spect the wheel bearings. 




Battery 

Pass through the battery case 
Pass through the frame 
Pass through the cable guide 
Pass through the engine bracket 



Battery 

Check the level of the battery electro- 
lyte and make sure that the terminals 
are tight. Fill with distilled water if the 
electrolyte level is low. If the motor- 
cycle is equipped with optional electri- 
cal accessories, the battery tends to 
discharge more quickly, so be sure to 
recharge it periodically. 



CAUTION: 



When inspecting the battery, be 
sure the breather hose is routed cor- 
rectly. If the breather hose is posi- 
tioned in such a way as to cause 
battery electrolyte or gas to exit 
onto the frame, structural and cos- 
metic damage to the motorcycle can 
occur. 



6-26 



PERIODIC MAINTENANCE AND MINOR REPAIR 



A WARNING 



Battery electrolyte is poisonous and 
dangerous, causing severe burns, 
etc. It contains sulfuric acid. Avoid 
contact with skin, eyes or clothing. 
ANTIDOTE: 

• EXTERNAL: Flush with water. 

• INTERNAL: Drink large quanti- 
ties of water or milk. Follow with 
milk of magnesia, beaten egg, 
or vegetable oil. Call a physi- 
cian immediately. 

• EYES: Flush with water for 
15 minutes and get prompt 
medical attention. 

Batteries produce explosive gases. 
Keep sparks, flame, cigarettes etc., 
away. Ventilate when charging or 
using in an enclosed space. Always 
shield your eyes when working near 
batteries. KEEP OUT OF REACH OF 
CHILDREN. 




1 . Maximum level mark 

2. Minimum level mark 

Replenishing the battery fluid 

A poorly maintained battery will cor- 
rode and discharge quickly. The bat- 
tery fluid should be checked at least 
once a month. The level should be be- 
tween the minimum level and maxi- 
mum level marks. Use only distilled 
water if refilling is necessary. 

EC000100 

CAUTION: 



Normal tap water contains minerals 
which are harmful to a battery; 
therefore, refill only with distilled 
water. 



Battery storage 

• When the motorcycle will not be 
used for a month or longer, re- 
move the battery, fully charge it 
and store it in a cool, dry place. 
Completely recharge the battery 
before reinstalling. 

• If the battery will be stored for 
longer than two months, check the 
specific gravity of the fluid at least 
once a month and recharge the 
battery when it is too low. 

• Always make sure the connec- 
tions are correct when putting the 
battery back in the motorcycle. 
Make sure the breather hose is 
properly connected and is not 
damaged or obstructed. 



6-27 



PERIODIC MAINTENANCE AND MINOR REPAIR 





iMt= 


^yV x^y/^/o^ 





CAUTION: 



1 . Main fuse 

2. Headlight fuse 

3. Signaling system fuse 

4. Ignition fuse 

5. Spare fuse (x 2) 

EAU00818 

Fuse replacement 

The fuse box is located under the rider 
seat. 

If any fuse is blown, turn off the main 
switch and the switch of the circuit in 
question. Install a new fuse of the spec- 
ified amperage. Turn on the switches 
and check if the electrical device oper- 
ates. If the fuse immediately blows 
again, consult a Yamaha dealer. 



Do not use fuses of higher amper- 
age rating than those recommend- 
ed. Substitution of a fuse of 
improper rating can cause extensive 
electrical system damage and pos- 
sibly a fire. 



Specified fuses: 




Main fuse: 


30 A 


Headlight fuse: 


15A 


Signaling system fuse: 


15A 


Ignition fuse: 


15A 



6-28 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1. Screw (x 2) 



Headlight bulb replacement 



CAUTION: 



It is advisable to have a Yamaha 
dealer perform this removal and re- 
assembly. 

If the headlight bulb burns out, replace 
the bulb as follows: 
1. Remove the screws holding the 
headlight unit. 



1. Coupler 

2. Bulb cover 



2. Disconnect the coupler and re- 
move the bulb holder cover. 



1. Bulb holder 

3. Turn the bulb holder counterclock- 
wise to remove it and remove the 
defective bulb. 



A WARNING 



Keep flammable products and your 
hands away from the bulb while it is 
on, as it is hot. Do not touch the bulb 
until it cools down. 

4. Put a new bulb into position and 
secure it in place with the bulb 
holder. 



6-29 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Reinstall the bulb holder cover, 
coupler and headlight unit. If the 
headlight beam adjustment is nec- 
essary, ask a Yamaha dealer to 
make that adjustment. 




1 . Screw (x 2) 

EAU00855 

Turn signal and taillight bulb 
replacement 

1 . Remove the screws and the lense. 



1. Bulb (x 2) 

2. Push the bulb inward and turn it 
counterclockwise. 

3. Place a new bulb in the socket. 
Push the bulb inward and turn it 
clockwise until it engages into the 
socket. 

4. Install the lense and the screws. 

EC000108 

CAUTION: 

Do not over-tighten the screws as 
the lense may break. 



6-30 



PERIODIC MAINTENANCE AND MINOR REPAIR 

EAU01008 

Troubleshooting 

Although Yamaha motorcycles receive 
a rigid inspection before shipment from 
the factory, trouble may occur during 
operation. 

Any problem in the fuel, compression, 
or ignition systems can cause poor 
starting and loss of power. The trouble- 
shooting chart describes a quick, easy 
procedure for making checks. 
If your motorcycle requires any repair, 
bring it to a Yamaha dealer. The skilled 
technicians at a Yamaha dealership 
have the tools, experience, and know- 
how to properly service your motor- 
cycle. Use only genuine Yamaha parts 
on your motorcycle. Imitation parts may 
look like Yamaha parts, but they are of- 
ten inferior. Consequently, they have a 
shorter service life and can lead to ex- 
pensive repair bills. 



6-31 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Troubleshooting chart 



PtlMMillllHJ 

Never check the fuel system while smoking or in the vicinity of an open flame. 



LFuel 



Check if there is fuel in 
the fuel tank. 



Enough fuel. 



Go to compression check. 



No fuel. 



Supply fuel. 



Engine doesn't start, go to compression check. 



2. Compression 




There is compression. 




Go to ignition check. 


Use the electric starter. 


— ►■ 
















No compression. 




Ask a Yamaha dealer to 
inspect. 









3. Ignition 




Wet. 




Wipe clean with dry cloth and correct 
spark gap or replace spark plug. 




Open throttle half-way and start 


Remove spark plug and 
check electrodes. 










the engine. 










" 


Dry. 




Ask a Yamaha dealer to inspect. 




Engine doesn't start, ao to batterv 








check. 





4. Battery 




Engine turns over 
quickly. 




Battery good. 




Use the electric starter. 


— ►- 












— »- 


Engine doesn't start, ask a Yamaha 
dealer to inspect. 














Engine turns over 
slowly. 




Check fluid, recharge, 
check connections. 

















6-32 



CLEANING AND STORAGE 



Cleaning 7-1 

Storage 7-2 



CLEANING AND STORAGE 



A. CLEANING 

Frequent, thorough cleaning of your 
motorcycle will not only enhance its ap- 
pearance but will improve its general 
performance and extend the useful life 
of many components. 



CAUTION: 



• Improper cleaning can damage 
the cowlings, panels and other 
plastic parts. Use only a soft, 
clean cloth or sponge with mild 
detergent and water to clean 
plastic. 

• Do not use any harsh chemical 
products on plastic parts. Be 
sure to avoid using cloths or 
sponges which have been in 
contact with strong or abrasive 
cleaning products, solvent or 
thinner, fuel (gasoline), rust re- 
movers or inhibitors, brake flu- 
id, antifreeze or electrolyte. 



1 . Before cleaning the motorcycle: 

a. Block off the end of the exhaust 
pipes to prevent water entry; a 
plastic bag and strong rubber 
band may be used. 

b. Make sure the spark plugs and all 
filler caps are properly installed. 

2. If the engine case is excessively 
greasy, apply degreaser with a 
paint brush. Do not apply degreas- 
er to wheel axles. 

3. Rinse the dirt and degreaser off 
with a garden hose. Use only 
enough pressure to do the job. 



CAUTION: 



Excessive hose pressure may cause 
water seepage and deterioration of 
wheel bearings, front fork, brakes, 
transmission seals and electrical 
parts. 

Many expensive repair bills have re- 
sulted from improper high pressure 
detergent applications such as 
those available in coin-operated car 
washers. 

4. After riding on salted roads, wash 
the motorcycle with cold water im- 
mediately. Do not use warm water 
as it increases the chemical reac- 
tion of the salt. 

5. Once the majority of the dirt has 
been hosed off, wash all surfaces 
with warm water and mild, deter- 
gent-type soap. An old toothbrush 
or bottle brush is handy for hard- 
to-get-at places. 



7-1 



CLEANING AND STORAGE 



6. Rinse the motorcycle off immedi- 
ately with clean water and dry all 
surfaces with a chamois, clean 
towel or soft absorbent cloth. 

7. Clean the seat with a vinyl uphol- 
stery cleaner to keep the cover pli- 
able and glossy. 

8. Automotive-type wax may be ap- 
plied to all painted and chrome- 
plated surfaces. Avoid combina- 
tion cleaner-waxes. Many contain 
abrasives which may mar the paint 
or protective finish. When finished, 
start the engine and let it idle for 
several minutes. 



B. STORAGE 

Long term storage (60 days or more) of 
your motorcycle will require some pre- 
ventive procedures to guard against 
deterioration. After thoroughly cleaning 
the motorcycle, prepare for storage as 
follows: 

1 . Fill the fuel tank with fuel and add 
fuel stabilizer (if available). 

2. Remove the spark plugs, pour 
about one tablespoon of engine oil 
in each spark plug hole and rein- 
stall the spark plugs. Turn the en- 
gine over several times (ground 
spark plug leads) to coat the cylin- 
der walls with oil. 



A WARNING 



When using the starter motor to 
crank the engine, remove the spark 
plug wires, and ground them to pre- 
vent sparking. 



3. Lubricate all control cables. 

4. Block up the frame to raise both 
wheels off the ground. 

5. Tie a plastic bag over the exhaust 
pipe outlets to prevent moisture 
from entering. 

6. If storing in a humid or salt-air at- 
mosphere, coat all exposed metal 
surfaces with a light film of oil. Do 
not apply oil to any rubber parts or 
the seat cover. 

7. Remove the battery and fully 
charge it. Store it in a cool, dry 
place and completely recharge it 
once a month. Do not store the 
battery in an excessively warm or 
cold place (less than 0° C (30° F) or 
more than 30°C (90°F)). See page 
6-27 for battery storage precau- 
tions. 

NOTE: 

Make any necessary repairs before 
storing the motorcycle. 



7-2 



SPECIFICATIONS 



Specifications 8-1 



SPECIFICATIONS 



Specifications 



Model 
Dimensions 

Overall length 

Overall width 

Overall height 

Seat hight 

Wheelbase 

Ground clearance 

Minimum turning radius 

Basic weight (with oil and full 
fuel tank) 

Engine 

Engine type 
Cylinder arrangement 
Displacement 
Bore x Stroke 
Compression ratio 
Starting system 
Lubrication system 



XV535/XV535C 

2,225 mm (87.6 in) 

780 mm (30.7 in) 
1,120 mm (44.1 in) 

720 mm (28.3 in) 
1 ,520 mm (59.8 in) 

160 mm (6.3 in) 
2,900 mm (114.2 in) 

195kg(430lb):XV535 
196kg(432lb):XV535C 

Air-cooled 4-stroke, SOHC 

V type 2-cylinder 

535 cm 3 

76.0 x 59.0 mm (2.99 x 2.32 in) 

9:1 

Electric starter 

Wet sump 



Engine oil 

Type 



Recommended engine oil 
classification 



CAUTION: 



0' 10' 30' 50' 70' 90' 110' 130'F 

I I I I I I I I 



YAMALUBE4(10W30) 
orSAE10W/30 



YAMALUBE 4 (20W40) 
orSAE 15W/40 



-20' -10' 0' 10' 20' 30' 40' 50'C 

API Service SE, SF, SG type or 
higher 



Be sure to use motor oils that do not contain anti-fric- 
tion modifiers. Passenger car motor oils (often labeled 
"Energy Conserving") contain anti-friction additives 
which will cause clutch and/or starter clutch slippage, 
resulting in reduced component life and poor engine 
performance. 



Quantity 

Periodic oil change 
With oil filter replacement 
Total amount 



2.6 L (2.3 Imp qt, 2.8 US qt) 
2.8 L (2.5 Imp qt, 3.0 US qt) 
3.2 L (2.8 Imp qt, 3.4 US qt) 



8-1 



SPECIFICATIONS 



Final gear oil 




Gear ratio 






Type 


SAE 80 API "GL-4" hypoid gear 






1st 


2.714 




oil 






2nd 


1.900 


Quantity 


0.19 L (0.17 Imp qt, 0.20 US qt) 






3rd 


1.458 


Air filter 


Dry type element 






4th 


1.167 


Fuel 








5th 


0.967 


Type 


Unleaded fuel 


Chassis 








Fuel tank capacity 


13.5 L (3.0 Imp gat, 3.6 US gal) 


Frame type 




Pressed backbone 


Reserve amount 


2.5 L (0.5 Imp gal, 0.7 US gal) 


Caster 


angle 




31.5° 


Carburetor 




Trail 






125 mm (4.92 in) 


Type x quantity 


BDS34 x 2 


Tires 








Manufacturer 


MIKUNI 


Front 








Spark plug 






Type 




With tube 


Type/Manufacturer 
Gap 


BP7ES / NGK or 
W22EP-U / DENSO 

0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 




Size 

Manufacturer/ 
model 


3.00-19 49S 
Bridgestone / L303A 


Clutch type 
Transmission 


Wet, multiple-disc 


Rear 






Dunlop/F14G 


Primary reduction system 


Spur gear 




Type 




With tube 


Primary reduction ratio 


1.944 




Size 




1 40/90- 15M/C 70S 


Secondary reduction system 


Shaft drive 




Manufacturer/ 




Secondary reduction ratio 


3.071 




model 




Bridgestone / G508 


Transmission type 


Constant mesh 5-speed 








Dunlop / K425 


Operation 


Left foot operation 











8-2 



SPECIFICATIONS 



Maximum load* 


220 kg (485 lb): XV53E 






Rear 










219kg(483lb):XV535C 






Type 


Drum brake 


Air pressure (cold tire) 










Operation 


Right foot operation 


Up to 90 kg load* 








Suspension 








Front 


200 kPa (2.00 kgf/cm 2 , 


29 


psi) 


Front 








Rear 


225 kPa (2.25 kgf/cm 2 , 


33 


psi) 




Type 


Telescopic fork 


90 kg 
load* 

* Load 
Wheels 


load - maximum 

Front 
Rear 
s total weight of cargo, 


200 kPa (2.00 kgf/cm 2 , 29 psi) 

250 kPa (2.50 kgf/cm 2 , 36 psi) 

rider, passenger and accessories. 


Rear 

Type 
Shock absorbers 

Front 

Rear 
Wheel travel 


Swingarm 

Coil spring / oil damper 
Coil spring / oil damper 


Front 


Type 
Size 


Spoke 
19xMT1.85 






Front 
Rear 
Electrical system 


150 mm (5.9 in) 
85 mm (3.4 in) 


Rear 


Type 
Size 


Spoke 
15M/CxMT3.00 






Ignition system 
Charging system 
Type 


T.C.I, (digital) 
A.C. magneto 


Brakes 

Front 


Type 

Operation 

Fluid 


Single disc brake 
Right hand operation 
DOT 4 or DOT 3 






Battery 


Standard output 

Type 

Voltage, capacity 


14 V, 24 A @ 5,000 r/min 

GM12AZ-3A-2 
12 V, 12 AH 



8-3 



SPECIFICATIONS 



Headlight type 


Bulb type 


Bulb voltage, wattage x quantity 




Headlight 


12 V, 65/60 Wx1 


Tail/brake light 


12 V, 8/27 Wx 2 


Front turn signal / position 
light 


12 V, 27/8 Wx2 


Rear turn signal light 


12 V, 27 Wx 2 


Meter light 


14 V, 3Wx1 


Neutral indicator light 


14 V, 3Wx1 


High beam indicator light 


12 V, 1.7 Wx1 


Turn indicator light 


14 V, 3Wx1 


Fuses 




Main fuse 


30 A 


Ignition fuse 


15A 


Signaling system fuse 


15A 


Headlight fuse 


15A 



8-4 



CONSUMER INFORMATION 



Identification number records 9-1 

Key identification number 9-1 

Vehicle identification number 9-1 

Model label 9-2 

Reporting safety defects 9-3 

Motorcycle noise regulation 9-4 

Maintenance record 9-5 

Street and enduro motorcycle limited warranty 9-7 

Yamaha extended service 9-9 



CONSUMER INFORMATION 



EAU02944 

Identification number records 

Record the key identification number, 
vehicle identification number and mod- 
el label information in the spaces pro- 
vided for assistance when ordering 
spare parts from a Yamaha dealer or 
for reference in case the vehicle is sto- 
len. 
1. KEY IDENTIFICATION 
NUMBER: 



O 



2. VEHICLE IDENTIFICATION 
NUMBER: 



3. MODEL LABEL INFORMATION: 




1 . Key identification number 

EAU01042 

Key identification number 

The key identification number is 
stamped on the key. Record this num- 
ber in the space provided and use it for 
reference when obtaining a new key. 



1 . Vehicle identification number 

EAU01043 

Vehicle identification number 

The vehicle identification number is 
stamped into the steering head pipe. 
Record this number in the space pro- 
vided. 

NOTE: 

The vehicle identification number is 
used to identify your motorcycle and 
may be used to register your motor- 
cycle with the licensing authority in 
your state. 



9-1 



CONSUMER INFORMATION 




1 . Model label 

EAU01050 

Model label 

The model label is affixed to the frame 
under the seat. (See page 3-7 for seat 
removal procedures.) Record the infor- 
mation on this label in the space pro- 
vided. This information will be needed 
to order spare parts from your Yamaha 
dealer. 



9-2 



CONSUMER INFORMATION 



Reporting safety defects 

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immedi- 
ately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying YAMAHA MOTOR CORP. 
U.S.A.. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in group 
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems 
between you, your dealer, or YAMAHA MOTOR CORP. U.S.A.. 

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1 -800-424-9393 (or 366-01 23 in Washington, D.C. 
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other informa- 
tion about motor vehicle safety from the Hotline. 



9-3 



CONSUMER INFORMATION 



Motorcycle noise regulation 

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: 

Federal law prohibits the following acts or the causing thereof: (1 ) The removal or rendering inoperative by any person other 
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve- 
hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of 
the vehicle after such device or element of design has been removed or rendered inoperative by any person. 

"AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW". 

These acts include tampering with the following systems; i.e., modification, removal, etc. 



Exhaust system 


Muffler 
Exhaust pipe 
Silencer 


Intake system 


Air cleaner case 
Air cleaner element 
Intake duct 



9-4 



CONSUMER INFORMATION 



MAINTENANCE RECORD 

Copies of work orders and/or receipts for parts you purchase and install will be required to document that maintenance has 
been completed in accordance with the emission warranty. The chart below is printed only as a reminder to you that the 
maintenance work is required. It is not acceptable proof of maintenance work. 



MAINTENANCE 
INTERVAL 


DATE OF 
SERVICE 


MILEAGE 


SERVICING DEALER 
NAME AND ADDRESS 


REMARKS 


600 mi 

(1,000km)or 

1 mo. 










4,000 mi 

(7,000km)or 

6 mos. 










8,000 mi 

(13,000km)or 

12 mos. 










12,000 mi 

(19,000km)or 

18 mos. 










16,000 mi 

(25,000 km)or 

24 mos. 










20,000 mi 

(31,000km)or 

30 mos. 










24,000 mi 

(37,000km)or 

36 mos. 











9-5 



CONSUMER INFORMATION 





MAINTENANCE 
INTERVAL 


DATE OF 
SERVICE 


MILEAGE 


SERVICING DEALER 
NAME AND ADDRESS 


REMARKS 


28,000 mi 

(43,000km)or 

42 mos. 










32,000 mi 

(49,000km)or 

48 mos. 










36,000 mi 

(55,000 km)or 

54 mos. 










40,000 mi 

(61,000km)or 

60 mos. 











9-6 



CONSUMER INFORMATION 



YAMAHA MOTOR CORPORATION, U.S.A. 
STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 



Yamaha Motor Corporation, U.S.A. hereby warrants 
each new model Yamaha motorcycle will be free from 
defects in material and workmanship for the period of 
time stated herein, subject to certain stated limitations. 

THE PERIOD OF WARRANTY for Yamaha motorcycles 
originally equipped with headlight, stoplight, and turn 
signals shall be one (1 ) year from the date of purchase, 
with no mileage limitation. 

MODELS EXCLUDED FROM WARRANTY include 
those used for non-Yamaha-authorized renting, leas- 
ing, or other commercial purposes, and TZ models. 

DURING THE PERIOD OF WARRANTY any authorized 
Yamaha motorcycle dealer will, free of charge, repair 
or replace any part adjudged defective by Yamaha due 
to faulty workmanship or material from the factory. 
Parts used in warranty repairs will be warranted for 
the balance of the product's warranty period. All parts 
replaced under warranty become property of Yamaha 
Motor Corp. U.S.A. 

GENERAL EXCLUSIONS from this warranty shall 
include any failures caused by: 

a. Competition or racing use. 

b. Installation of parts or accessories that are not 
qualitatively equivalent to genuine Yamaha parts. 

c. Abnormal strain, neglect, or abuse. 

d. Lack of proper maintenance. 

e. Accident or collision damage. 

f. Modification to original parts. 

SPECIFIC EXCLUSIONS from this warranty shall 
include parts replaced due to normal wear or routine 
maintenance. 



THE CUSTOMER'S RESPONSIBILITY under this war- 
ranty shall be to: 

1. Operate and maintain the motorcycle as specified 
in the appropriate Owner's Manual, and 

2. Give notice to an authorized Yamaha motorcycle 
dealer of any and all apparent defects within ten 
{10) days after discovery, and make the machine 
available at that time for inspection and repairs at 
such dealer's place of business. 

WARRANTY TRANSFER: To transfer the warranty 
from the original purchaser to any subsequent pur- 
chaser, it is imperative that the machine be inspected 
and registered for warranty by an authorized Yamaha 
motorcycle dealer. In order for this warranty to remain 
in effect, this inspection and registration must take 
place within ten (10) days after transfer. An inspection and 
registration fee will be charged for this service. 

EMISSIONS CONTROL SYSTEM WARRANTY 

Yamaha Motor Corporation, U.S.A. also warrants to the 
ultimate purchaser and each subsequent purchaser of 
each Yamaha motorcycle covered by this warranty 
with a displacement of 50cc or greater, that the vehi- 
cle is designed, built, and equipped so as to conform 
at the time of sale with all U.S. emissions standards 
applicable at the time of manufacture and that it is free 
from defects in materials and workmanship which 
would cause it not to meet these standards within the 
periods listed immediately below. Failure other than 
those resulting from defects in material or workman- 
ship which arise solely as a result of owner abuse 
and / or lack of proper maintenance are not covered by 
this warranty. 



ENGINE 

DISPLACEMENT PERIOD 

50ccto 169cc 12,000 km (7,465 miles) 

or five years, whichever occurs first 

170ccto279cc 18,000 km (11,185 miles) 

or five years, whichever occurs first 

280cc or over 30,000 km (18,641 miles) 

or five years, whichever occurs first 

YAMAHA